Air permeable composite for seating applications
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Solution Overview
Problem
Current perforated nonwoven suedes used in seating applications face challenges in achieving sufficient airflow and aesthetic features due to the limitations of air permeability when a decorative scrim is added to the back, resulting in airflow rates significantly lower than standards, often as low as 20 CFM.
Innovation Solution
A breathable backing scrim layer with aesthetic features is applied to a perforated nonwoven suede layer using adhesives like spun-laced, heat-activated, or powder adhesives to form a composite material that enhances airflow while maintaining aesthetic visibility through perforations, achieving airflow rates of at least 115 CFM.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a decorative scrim is added to the back of perforated materials, then aesthetic features are improved, but air flow is significantly reduced
Solution Approach 1:
The patent applies porous materials by using a breathable scrim with high porosity (at least 20% open area) that allows air to pass through while providing aesthetic features. The porous structure enables the scrim to maintain visual appeal through color and texture while permitting sufficient airflow (at least 115 CFM) to meet heated and cooled seat requirements.
2Shape
If typical composite of perforated face and decorative backing materials is used, then aesthetic features are achieved, but air permeability drops to as low as 20 CFM
Solution Approach 1:
The patent applies composite materials by combining a perforated face material with a specifically engineered breathable scrim backing in a composite structure. This composite achieves both aesthetic features through the scrim's color and texture while maintaining reliability through sufficient air permeability (at least 115 CFM), overcoming the limitation of typical composites that drop to 20 CFM.
3Productivity
If airflow specification is met through perforations, then heating and cooling functionality is achieved, but aesthetic features are limited
Solution Approach 1:
The patent applies segmentation by separating the functions of airflow and aesthetics into two distinct layers: the perforated face material handles airflow requirements for heating and cooling functionality, while the breathable scrim backing provides aesthetic features through color and texture that are visible through the perforations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly improves air permeability and tear strength of the composite material, ensuring it meets seating application requirements while displaying aesthetic features, with airflow rates up to 600 CFM and tear strength of over 100 N, balancing breathability and strength.
Implementation Method 1
A breathable backing scrim layer with aesthetic features is applied to a perforated nonwoven suede layer using adhesives like spun-laced, heat-activated, or powder adhesives to form a composite material
Data Source
AI summary
A composite formed by combining a perforated face layer and a backing scrim to make a material having sufficient airflow, tear strength and aesthetic features applicable to seating.